Ford Falcon. Manual — part 128

303-01b-26

Engine — 5.4L (3V)

303-01b-26

IN-VEHICLE REPAIR (Continued)

7. Remove the crankshaft sprocket.

12. Remove the bolts and the variable camshaft

timing housing.

8. Remove both timing chain guides.

Discard the gasket.

CAUTION: Unless otherwise instructed, at

no time when the timing chains are removed

and the cylinders heads are installed is the

crankshaft or camshaft to be rotated. Severe

piston and valve damage will occur.

Remove the bolts.
Remove both timing chain guides.

13. Repeat steps 9 to 11 for removal of LH

components.

Installation
1. Install a new gasket, the variable camshaft timing

housing and the bolts.

9. Fit the SST 303-775 to camshaft in the central

position between caps and tighten to prevent

rotation.

WARNING: When tightening hex key bolts

on SST 303-775 make sure both bolts are

tightened evenly.

2. Install the RH camshaft variable timing sprocket

assembly and loosely install a new bolt and

washer.

10. Remove bolt and washer on RH camshaft.

CAUTION: Apply an even force on hand

tools to remove the camshaft phaser sprocket

assembly or damage may occur to the

camshaft or camshaft phaser unit.

11. Discard RH Phasor sprocket.

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303-01b-27

Engine — 5.4L (3V)

303-01b-27

IN-VEHICLE REPAIR (Continued)

3. With SST303-775 in place holding the camshafts, 8. Pre-position the camshafts.

tighten the bolts in two stages

Rotate the LH camshaft until the timing mark

Stage 1: Tighten to 40 Nm.

is approximately at 12 o’clock.

Stage 2: Tighten an additional 90 degrees.

Rotate the RH camshaft until the timing mark

is approximately at 11 o’clock.

CAUTION: Only use hand tools to

remove the camshaft phaser sprocket

assembly or damage may occur to the

camshaft or camshaft phaser unit.

4. Repeat steps 1 to 3 for the LH camshaft phaser

sprocket.

5. Compress the tensioner plunger, using a vice.

CAUTION: Timing chain procedures must

be followed exactly or damage to valves and

pistons will result.

9. Position the crankshaft so the number on cylinder

is at TDC using special tool 303-448
NOTE: The number one cylinder is at top dead

centre (TDC) when the stud on the engine block

fits into the slot in the handle of the special tool.

6. Install a retaining clip on the tensioner to hold the

plunger in during installation.
NOTE: If the retaining clip is not available insert a

paper clip into the tensioner spring hole.

10. Install the timing chain guides

7. Remove the tensioner from the vise.

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303-01b-28

Engine — 5.4L (3V)

303-01b-28

IN-VEHICLE REPAIR (Continued)

11. Remove the crankshaft holding tool

13. If copper links are not visible on timing chains,

hold chains straight mark two links on one end

12. Install the crankshaft sprocket, making sure the

and one link on the other end and use as timing

flange faces forward.

marks.

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303-01b-29

Engine — 5.4L (3V)

303-01b-29

IN-VEHICLE REPAIR (Continued)

14. Position the lower end of the LH (inner) timing

16. Position the LH timing chain tensioner arm on the

chain on the crankshaft sprocket, aligning the

dowel pin and install the LH timing chain tensioner

timing mark on the outer flange of the crankshaft

bolts.

sprocket with the single copper link (or single

NOTE: The LH timing chain tensioner arm has a

marked link) on the chain.

bump near the dowel hole for identification.

15. Position the timing chain on the camshaft

17. Remove The retaining clip or paperclip from the

sprocket with the camshaft sprocket timing mark

LH timing chain tensioner.

positioned between the two copper (marked)

chain links.
NOTE: Make sure the upper half of the timing

chain is below the tensioner arm dowel.

18. Position the lower end of the RH (outer) timing

chain on the crankshaft sprocket, aligning the

timing mark on the sprocket with the single copper

(marked) chain link.

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